Diesel In-tank Fuel Pump Replacement - Can’t get assembly back in

Toby Waters · 25th July 2021, 18:36

Hi there,

I’m currently in the process of replacing the in-tank fuel pump on my facelift Rover 75 using the how-to guide. New pump fitted, electrical connections made etc. and managed to fit it all back in the tank but it isn’t seating properly, feels like it’s a couple of mm proud and the retaining ring won’t go on.

Any idea what might be stopping it? Or is there a knack to refitting?

I tried lifting the assembly out and putting it back in at slightly different angles for about 1/2 hour but no luck. No sign of pipe work underneath. I did have some fun working out how to get the large separate plastic section back in (as mine looked quite different to the one pictured) but directed it to the near side rear wheel and it seems to leave enough space for the pump assy.

Many thanks,
Toby

T-Cut · 26th July 2021, 09:01

Check out the HowTo on replacing the filter module and the seals. The tank port seal is a regular cause of problems and must be fitted correctly to get the filter (or pump) module to sit low enough. The clamping ring should start and turn on the port thread without force. Just follow the relevant section near the end.

HowTo: https://www.the75andztclub.co.uk/for...ead.php?t=9108
TC

Toby Waters · 26th July 2021, 14:07

Thanks TC,

The original seal was still attached to the fuel pump assembly when I went to refit. I then replaced (hopefully the correct way up) and tried to refit the seal and assembly as one. Sounds like I need to get the seal seated first then insert the pump assembly. Fingers crossed this will help!

T-Cut · 26th July 2021, 17:08

Yes, fit the seal around the port lip first. It can't be done any other way. The lip fits into a 'groove' around the lower edge of the seal. Ensure the 'tongue' on the pump module is aligned with the cutaway on the port lip. This ensures the float arm will stand clear on the inside of the tank.

TC

25th July 2021, 18:36	#1
Toby Waters Avid contributor Rover 75 Saloon (CDTi) Join Date: Nov 2008 Location: Bromley Posts: 110 Thanks: 3 Thanked 3 Times in 3 Posts	Diesel In-tank Fuel Pump Replacement - Can’t get assembly back in Hi there, I’m currently in the process of replacing the in-tank fuel pump on my facelift Rover 75 using the how-to guide. New pump fitted, electrical connections made etc. and managed to fit it all back in the tank but it isn’t seating properly, feels like it’s a couple of mm proud and the retaining ring won’t go on. Any idea what might be stopping it? Or is there a knack to refitting? I tried lifting the assembly out and putting it back in at slightly different angles for about 1/2 hour but no luck. No sign of pipe work underneath. I did have some fun working out how to get the large separate plastic section back in (as mine looked quite different to the one pictured) but directed it to the near side rear wheel and it seems to leave enough space for the pump assy. Many thanks, Toby

26th July 2021, 09:01	#2
T-Cut This is my second home Rover75 and Mreg Corsa. Join Date: Nov 2006 Location: Sumweer onat mote o'dust (Sagin) Posts: 21,752 Thanks: 341 Thanked 3,660 Times in 2,924 Posts	Check out the HowTo on replacing the filter module and the seals. The tank port seal is a regular cause of problems and must be fitted correctly to get the filter (or pump) module to sit low enough. The clamping ring should start and turn on the port thread without force. Just follow the relevant section near the end. HowTo: https://www.the75andztclub.co.uk/for...ead.php?t=9108 TC

26th July 2021, 14:07	#3
Toby Waters Avid contributor Rover 75 Saloon (CDTi) Join Date: Nov 2008 Location: Bromley Posts: 110 Thanks: 3 Thanked 3 Times in 3 Posts	Thanks TC, The original seal was still attached to the fuel pump assembly when I went to refit. I then replaced (hopefully the correct way up) and tried to refit the seal and assembly as one. Sounds like I need to get the seal seated first then insert the pump assembly. Fingers crossed this will help!

26th July 2021, 17:08	#4
T-Cut This is my second home Rover75 and Mreg Corsa. Join Date: Nov 2006 Location: Sumweer onat mote o'dust (Sagin) Posts: 21,752 Thanks: 341 Thanked 3,660 Times in 2,924 Posts	Yes, fit the seal around the port lip first. It can't be done any other way. The lip fits into a 'groove' around the lower edge of the seal. Ensure the 'tongue' on the pump module is aligned with the cutaway on the port lip. This ensures the float arm will stand clear on the inside of the tank. TC